Up Close: Tacoma Chief Engineer Goes Deep
By Peter A. Hubbard
The nearly 300 attendees at this year's 10th Annual Lone Star Toyota Jamboree held at the Barnwell Mountain Recreation Area in Gilmer, Texas (120 miles east of Dallas), came expecting to spend four days doing off-road trail rides and sampling the wares of the roughly 35 sponsoring Toyota-loving vendors.
What they did not expect was a surprise appearance by Michael Sweers, Toyota's chief engineer for the all-new 2016 Toyota Tacoma. He and his crew have been working on the midsize pickup truck for three years, and they brought one to the jamboree. We caught up with Sweers as he was conducting walk-arounds and collecting feedback from event participants.
PUTC: Up until now the only place the 2016 Tacoma has been on display has been at major auto shows. What made you decide to bring it out to an off-roading event like this?
Sweers: All the [jamboree] attendees are Toyota owners. They love Toyota and are very loyal to the brand, so it seemed like the logical place to come and show off our all-new Tacoma, and to demonstrate some of its new features and capabilities. We figured these were the kinds of Toyota owners who would really appreciate seeing it themselves.
PUTC: What are some of the major changes and upgrades you've made to the new Tacoma?
Sweers: The truck is all new from the ground up. We focused on several different things. But overall, our main goal here was to build the best and baddest truck we could come up with. To start that process we talked to a lot of our current Toyota Tacoma owners and asked them what they would change, if they could change something about the truck. We asked them to tell us what they wanted that wasn't available, or wasn't built into the current truck.
Compared with our competition, we've gone in a slightly different direction. The main focus for us wasn't to make a baby Tundra, but to do a better job of delivering what this particular demographic is after. We're trying to really meet the needs of that younger, more active crowd. We took a very close look at how they used their trucks, and really scrutinized what kinds of items they hauled in their truck and towed with their truck. So whether it was hauling dirt bikes, personal watercraft or ATVs [all-terrain vehicles], we wanted to make sure we were meeting their needs — and at the same time keeping our SAE [Society of Automotive Engineers] certification for the J2807 [towing standards]. So we're right around 6,800 pounds, which adds 300 [pounds] more towing capacity. Other than that we simply wanted to improve and upgrade certain areas to improve the overall QDR [quality, durability and reliability] of the truck.
Based on that feedback, a couple of things come to mind. First of all, we installed a new rear differential and took the electric motor for the e-locker from outside the differential and added internal solenoids to do that job instead.
Customer suggestions also resulted in us putting a GoPro camera mount inside the windshield. Those were just some of the responses that we got. They told us, "These are the things I've done on my own to improve my truck, or these are the kinds of things we'd like to see, that can only be done at the factory."
So the direction we've taken with the 2016 may be a little different than the path taken by our competition, because we really focused on pleasing our current buyers and the demographic group that is the primary target market for our truck. We have the most active customers and we have the youngest customers, and they tend to use the truck as a truck, not a car.
PUTC: Were there other upgrades or changes your customers wanted to see?
Sweers: Improving fuel economy for the Tacoma was one of the main things customers asked us to do. So we focused on reducing the drag coefficient of the truck and making it more aerodynamic — which isn't easy to do when you have a vehicle that sits so high off the ground. But we managed to do it. As a result, it has the lowest coefficient of drag of any truck in the segment. And it did help improve fuel economy.
We really weren't able to take much weight out of the truck; however, we added some lightweight materials in an effort to improve economy, but those efforts were offset when some new components were added. The main reason was we went to ultra-high-strength steel to make the body structure [stronger].
Another change we made to improve fuel economy was to add a more efficient 3.5-liter Atkinson-cycle V-6 engine. Not only is it more efficient, we are mating it with two new transmissions — a six-speed automatic and a new six-speed manual. We also added an all-new transfer case in the truck, and the new rear differential that I mentioned earlier, adding high-strength steel to the axle housing, and changed how the e-locker is engaged, for better protection.
PUTC: Can you talk about the styling changes for 2016 and what Toyota's thoughts were?
Sweers: The exterior styling is basically set to give the appearance of an aggressive desert racer. The interior styling is based off some of the ATV styling themes we're seeing now, with the handlebar design in front.
We also cleaned up the model lineup so each model or grade has a clearly defined look — both inside and out — with certain standard equipment packaged into each one. We will be coming out with five distinct models — the SR, the SR5 and the Limited, followed by our TRD Sport and TRD Off-Road models.
The SR5 continues to be our top seller. Meanwhile, the new two-door TRD Sport is a 4x4 for the average customer, while the Off-Road is more for those who are seriously into the 4x4 experience. That gives you the locking differential and better shocks, so the spring rates have been changed. If you go with the four-door we offer the four-door TRD Off-Road model, with higher spring rates in both the front and the rear.
We really focused on providing much better ride quality on models with the off-road packages. They used to be really harsh. So this time we've worked to round the edges off a bit more. They still do the job of giving you good off-road handling ability, without shaking the fillings loose from your teeth.
In the process of improving the aerodynamics of the new 2016 Tacoma, one of the things we wanted to focus on was making sure we didn't do anything to take away from the truck's off-road capability. So our approach and departure angles are still best in class for both the standard and off-road models. Our brake-over angle overall is 29 degrees, with a figure of 21 degrees in back and 31 degrees in back, both best-in class figures.
PUTC: Did the dimensions change much?
Sweers: We seriously looked at making dramatic changes to the packaging of the truck. But after lots of consideration and debate, as well as talking extensively with our current owner body, we decided to keep essentially the same size for the overall package. Now we did make the cabin slightly larger inside … we'll offer a bit more hip room and shoulder room. So with that our customers get a bit more wiggle room. Essentially we're working to provide a cabin that overall is more spacious and comfortable.
The wheelbase of the truck is the exactly the same, but the overall length is 107 millimeters longer [just more than 4 inches]. We added 97 millimeters [3.82 inches] in the front and 10 millimeters [almost a half inch] in the rear. The front overhang was increased to accommodate future pedestrian safety requirements that the industry anticipates will be coming from the National Highway Transportation Safety Administration by 2018. We expect these will be similar to what is currently in effect in Europe, which requires a change in the bumper configuration of trucks and commercial vehicles.
Also, we raised the hood 30 millimeters [just more than an inch] and the deck 33 millimeters to accommodate other customer requests as well as some production requirements.
Customers also said they'd like greater stability, so we increased the rigidity. We accomplished that by using ultra-high-strength steel not only in the body panels, but in the frame as well. So the front portion of the frame is all new, and the control arms have been beefed up. To give the buyers better corrosion resistance we changed up the coating material we use on the frame for 2016. We also went to nylon-coated brake lines to provide longer life and better corrosion resistance.
PUTC: Earlier you mentioned the all-new V-6 engine. Can you describe what other changes or upgrades were made to the powertrain?
Sweers: We carried over the same base four-cylinder engine, but did make some friction-reducing changes internally that will help improve fuel economy. Now the V-6 is an Atkinson cycle with a very fuel-efficient direct-injection system, plus port injection.
That engine is brand new for 2016, and exclusive to this truck in the American market. No other Toyota or Lexus model offers it. It's being built for us at our engine plant in Alabama. And then we have our new six-speed manual transmission as well as a new six-speed automatic, which will both help improve fuel economy. So the gearing is now 28 percent lower on the front end and 22 percent higher on the rear end of the power band. So getting off the line, we've got a little lower gear now in the manual.
We changed the ratios in our rear differential as well. We're now offering a 3.9:1 and a 4.3:1. Previously we offered five different ratios for the rear end, but realized for the usage our customers have, we just didn't need that many in this truck, so we're just going with the two for 2016.
PUTC: What are the major changes to the interior?
Sweers: I already mentioned a couple of things — adding more shoulder and hip room, and installing the GoPro camera mount. But we also have wireless USB port charging available now on the center of the instrument panel. Another addition is one-touch power-up, power-down windows.
We also changed the instrument display so the gauges are easier to see and read. The audio system has also been upgraded in the new truck to improve the sound quality. But perhaps the biggest change we made to the interior is the quietness inside the cabin of the truck. We added extra sound-deadening acoustic materials on the various metal surfaces, including the firewall, floor and ceiling of the truck.
Next, we put improved sealant between the cab and the rear deck where the truck box sits. We also changed the door hinge flange so there is less noise when opening and closing the door of the truck.
PUTC: What kind of response have you gotten from attendees?
Sweers: The feedback has been largely positive. Those attending generally approve of the more aggressive look of the new truck and the fact we were able to make it more aerodynamic without sacrificing strength or rigidity. They also approved of the change we made to the e-locker, going with internal controls so it's less susceptible to being damaged or being affected by moisture. They also like the fact we added a camera mount inside the cab.
If there has been an area of concern it was with the front bumper. With the anticipated change coming from NHTSA regarding bumper design, we wanted to be out front instead of reacting to the rule change later on. However, some were concerned it might be more difficult to attach personalized aftermarket bumpers to the new Tacoma.
Cars.com photos by Peter Hubbard
Comments
This might be a little dorky.. but one of my favorite features in a vehicle is the one-touch up-down window controls! Overall the truck looks good. A nice step up from the current gen. This gen will be highly considered when I purchase my first truck. Good job Toyota.
i appreciate toyotas reputation fpr reliability. however between the tacoma and tundra neither meets my wishes. looking for a pu/suv that can tow 7700# and get 28-30 hwy mpg. my short list (5) contains 3 vehicles that aren't evan out yet, one being the colorado zr2 with the baby duramax. toyata refuses to bring out a diesel which would help both towing and mpg's. sorry toyota i'll be looking elsewhere!
When will we seen MPG numbers and horsepower and torque numbers for the V6 engine?
Why spend time and money developing 6 speed autos for this truck when the industry is at 8 or 9 speed autos and going to 10 speed autos (Ford & GM)? Toyota is coming out of the gate with old technology, 6sp auto.
Any other fuel saving technologies like electric power steering? Variable displacement oil pump?
The 6 speed automatic should have been installed a half decade ago.
Where is the 8 speed automatic?
So if this is a real atkinson cycle engine, does that mean the engine will only make ~270hp. Toyota/Lexus has promised 300hp in the '16 Lexus RX350.
And it is 2015, where is the center differential?
That dirty brown "desert sand mica" color was voted the ugliest on TacomaWorld.
Latest oxi comment on PUTC facebook....
No suprise as to why the old and always ripped on Tacoma continues to outsell the darling Colorado 2 to 1... folks just know a good pickup when they see one in mid-sized class! No joke, best re-sale value among ALL vehicles does play a huge role in that, something the Colorado will never have!
@frank,
oxi says...
NOOOOOOOOOOOOOOOOOO! Current pickup owners cannot even handle driving what they currently have, this would be a big mistake and a danger to the motoring public!
When I can take my 1.8 liter Toyota Corolla and blow by high-hp sports cars in the corners because their drivers are incompetant, why give them a high-hp pickup higher off the ground!
@mike shank in
Is that 28-30 mpg in diesel or 28-30 mpg in gasoline. There is a difference in price especially in the winter months if you you are doing this for cost reasons. A vehicles that gets 28-30 mpg in diesel is cost equivalent to a 23-26 mpg gasoline engine depending on where you live.
Too little, too late. Same 4-pot. No more regular cabs, but look we have a GoPro camera mount - Ugh! What this country needs is a SMALL regular cab pick up with a diesel, standard tranny and 4x4.
Too little, too late. Same 4-pot. No more regular cabs, but look we have a GoPro camera mount - Ugh! What this country needs is a SMALL regular cab pick up with a diesel, standard tranny and 4x4.
Another Home Run from Toyota.
I am trying to talk my wife out of a new Acura MDX and get the Tacoma Off Road, so I will have something to play with in West Texas Desert, since I am not giving up the Tundra CM for work (and play).
Life is much better since I gave up Ford, GM, and Ram.
I agree with oxi...
OXI's responses:
First of all just look at this Tacoma and tell me the competition in class does not even come close for off-road ability...This thing is built better for off-road, no torsion bars hanging too low or mounted on the lower a-arms or lower shock mounts in odd positions begging to get hit.
Hech even when Toyota had torsion bar fronts, they were the only company to mount them on the upper a-arm thus full frame protection! And I cannot tell you about mounting leaf springs above the axle back then while the domestics were below the axle.
Result was a taller truck, more running ground clearance and very easy to fit larger tires underneath. That is what sold me back in the day to buying a Toyota. Crap, just crank the front t-bars a bit, add a leaf in the rear and 35x12.5 BFG's fit no problem.
Try that with your little Ranger, Dakota or S-10!
Today, same story where the Tacoma is fit for off-road duty while the domestics are like low-riders. I can spend less with a Tacoma to mount larger tires than probably the big 3 combined! That is what sells to me concerning off-road ability.
You can say what you want about looks, tires from the factory (who gives a hoot, I always change them anyway to larger BFG's, I already took off my 245/75 Dunflops and placed proper 265/75 BGF A/T KO's on my Tacoma), too big or whatever but the Tacoma sells because it caters to more people by offering more configurations and styles.
I tend to buy one as close to stripped as I can, very hard these days and build it up myself.
My Tacoma has been solid so far through 7,000 miles and I am off-roading this weekend with her with various types of rigs, mostly solid front guys but I will be there showing how a standard Tacoma can do it like the hard-core guys can!
My 2012 Tacoma couldn't keep the air conditioning working and after 4 trips the dealership and never getting any resolution, I sold that truck and have never missed it one day! I won't be interested in this new Tacoma AT ALL.
Liars this thing is not all new. It is significantly updated but rides on the same old platform.
"All new from the ground up." That cab looks just like my 2006 where you are practically sitting on the floor.
"We really focused on providing much better ride quality on models with the off-road packages." The standard models have a lousy ride. Please tell me those are improved.
I really wanted to like this, but can't bring myself to spend $30K for a truck that I already have and don't particularly like other than the reliability.
Randy said (I am trying to talk my wife out of a new Acura MDX and get the Tacoma Off Road0
You can probably buy two Tacomas for price of a mdx
but the mdx is in whole different class than anything Toyoda makes. and just as reliable.
I had a new Tacoma once..for 3 miserable weeks. I wish I had taken it home overnight and driven it a couple of hours. Most uncomfortable vehicle I ever sat in ..>ok for 20 minutes, then my legs would start to feel pins and needles. My pain doctor (I have spinal stenosis) explained the seat was too low to the floor. ALMOST EVERY REVIEW OF THE TACO SAYS THE DRIVERS SEAT IS MISERABLE. DID YOU FIX THAT MIKE SWEERS. Or did you just mount the camera fixture and call it "all new."
Another Toyota fail. Two in a row with the "new Tundra #1. I love Toyotas and I love my Tundra..but we will have to part ways at the next purchase.
Sweers didn't talk much about the vehicles NVH or for that matter much on the suspension.
One thing noted from his comments is the next V6's fuel injection setup, port and direct.
This indicates to me that future gasoline engines will have to improve their particulates emission standards.
At the moment GDI engines are far worse emitter of particulates than diesels engines.
Other than that the changes should keep the Taco as is for several more years.
He did talk up the changes, the newer midsizers are a better proposition than this rendition of the Taco. But sooner or later Toyota will not have the luxury of living on the name it made in the 80s and 90s.
If a six speed is a big deal for the Taco, then I do see a gradual slowdown of the Taco over the next 4 years or so.
That's what happened to the Hilux here. It's lost market share as a percentage because the newer midsizers are far better products.
As I stated Toyota can't live on the past. The Taco is a very reliable and overpriced vehicle for what it is, but so is my Briggs and Stratton powered lawn mower with it's flat head technology.
Time will tell.
Running direct and port injection is the new way to try and stop carbon build up on intake valves other manufacturers ford bmw vw audi have all seen this problem. on a non turbo eng a cleaner like seafoam can be used. sorry ecoboost your turbo will fry. using a port injector in the intake to fire every so offen will help keep the back side of the intake valves cleaner.
Not being 'brand loyal',I have no dogs in this fight.having said that I can't help but wonder how the new gm diesel twins will do against the 'new' taco.I have a feeling it won't be pretty for toyota.
I dont have much to complain on the "new" taco but i do wish they dont jack up the price tremendously. Forget about reducing the price--which almost never happen in automakers--instead make it marginally the same price as the previous taco or the colorado.
A base V6 with regular cab with the towing package for right around 25-26k is reasonable for me.
A blind man can see he doesn't look like he belongs dressing in those jeans, tee shirt and hat.
Just another suit pretending to look like a redneck.
@MIKE,
The build up is caused by particulates.
There has been much discussion regarding gasoline engine particulate emisssions over the past couple of years.
It seems the vehicle manufacturers are dragging the chain. The additional cost per vehicle is quite high to reduce particulates.
You can use port injection or a DPF.
My 2012 Tacoma couldn't keep the air conditioning working and after 4 trips the dealership and never getting any resolution, I sold that truck and have never missed it one day! I won't be interested in this new Tacoma AT ALL.
I don't miss my 2012 total pos, best day was when I traded it in on my 2013 F-150
I've loved the small toyota trucks since 1983. What I miss is the round wheel wells that made it easier to lift the truck a few inches and fit 33" tires. The irregular shape that Toyota took a while back makes lifting more difficult. I would also like to see a true for lack of a better word "raptor capable" tacoma. That being said, I'm grateful that GM has charged full speed into the midsize truck market. I believe the competition has driven Toyota to finally start improving the truck that has set idle for the better part of a decade. I will certainly look at the new Tacoma for my son who will be driving in a couple of years. Hopefully, the price wont go through the roof like the new F-150 did.
I've loved the small toyota trucks since 1983. What I miss is the round wheel wells that made it easier to lift the truck a few inches and fit 33" tires. The irregular shape that Toyota took a while back makes lifting more difficult. I would also like to see a true for lack of a better word "raptor capable" tacoma. That being said, I'm grateful that GM has charged full speed into the midsize truck market. I believe the competition has driven Toyota to finally start improving the truck that has set idle for the better part of a decade. I will certainly look at the new Tacoma for my son who will be driving in a couple of years. Hopefully, the price wont go through the roof like the new F-150 did.
I am glad to see the Tacoma has been updated for 2016. I prefer the Colorado/Canyon twins but would not rule out either the Tacoma or the Frontier. I don't mind the beige color on this truck--it is neutral and is hides dirt better. This beige reminds of the beige Kia uses on the Soul and of the Desert Sand color my parents had on a 1964 Impala wagon.
@ Big Al
GDI may very well have more particulates but the carbon build up on valves is because gasoline never passes by the intake valves cleaning the surface allowing the carbon build up excessively quick.
I have read a within the last couple years that this is Toyotas solution to the problem, more power and fuel efficiency with direct injection but kept port for reliability.
Is their a uglier color than that poop brown?
Just terrible
Same turd, different color.
He said that people what a higher hood? I would think lower for better off-road visibility?
He also said they made the off-road with a softer ride, which is great. I had my Taco for 300 miles and took off the super stiff Bilseins and put a set of softer Rancho's and it made all the difference
"Up Close: Tacoma Chief Engineer Goes Deep"
Am I the only one who thinks this sounds dirty?
Enjoyed reading the comments more than the article.
What is this NHTSA pedestrian safety b.s.? If you think adding a couple of inches onto the front of a vehicle is going to make a bit of difference in pedestrian safety, I beg to differ. I say just more nonsense from a bunch of bureaucrats that have to think up ways to further destroy our trucks! Until we get a handle on this crap we are all doomed to pay hugely for vehicles that in reality will do less and less only with more creature comfort (aka a bunch of nonsense items that nobody actually can use while driving) and safety features for those that do not try to avoid wrecks by focusing on driving. The Tacoma is still a capable truck, but for the price they are asking for them, you are better off getting a much larger truck.
Lame looking Tacoma adding 4 inches in length is going backwards, bad mpg, no 2 door regular cab, no diesel. Still holding out hope that Nissan will bring the good looking navarra here without growing it in size and adding a diesel you will finally see it outsell Tacoma then with better looks, better mpt and more manaegable size
Lame looking Tacoma adding 4 inches in length is going backwards, bad mpg, no 2 door regular cab, no diesel. Still holding out hope that Nissan will bring the good looking navarra here without growing it in size and adding a diesel you will finally see it outsell Tacoma then with better looks, better mpt and more manaegable size
@ Alberta_85,
Here's a couple of good links to have a read of.
The deposit buildup in the GDI engines is caused by particulates.
EuroVI and CARB/EPA will not allow the levels of particulates to be emitted from current GDI engines.
This change is coming quite soon.
I would like to see how Ford, which is the biggest user of turbo engines in mainstream vehicles rectify this problem.
I've read some articles claiming that vehicles will use slightly more fuel to using less fuel with either a DPF or added port injection.
The particulates from a GDI engine are at their highest when the engine is cold, similar to a diesel.
The build up you are talking about is carbon, carbon is soot, no different than diesel particulates.
http://papers.sae.org/2011-01-1219/
http://articles.sae.org/13624/
http://www.greencarcongress.com/2014/01/2014014-audi.html
the hilux is 100x better
the hilux is more suitable in canada because the roads are bumpy and the weather makes more potholes than the states
@ Bret Tidwell - What kind of idiot buys his child a brand new vehicle. You're the reason kids are entitled assholes nowadays.
I'm glad they didn't, " try to make a baby Tundra", if a Tundra is what Toyota thinks is a great example of a pickup to be emulated in their midsizer, you'd really have to wonder about their sanity! Taking a POS and downsizing it , doesn't make for anything but a smaller POS! The Taco at least has been a decent little rig over the years.
Sweers isn't the chief engineer he is the chief of PR!
All new??????
"All New" is the most abused term used in the auto industry.
@Lou_BC--All new reminds me of "New and Improved" in consumer staples which translates as a new package and less product.
You know, it's nice that they asked all their current owners what would convince them to remain loyal, but why didn't they ask non-owners... people who want a truck but haven't bought one? Why didn't they ask SUV/CUV owners why they chose what they did over a truck? They might have discovered a way to generate new business--new sales--experience more growth and more profits from all-new customers. Giving current customers what they want only ensures you keep current customers. Going outside of the box and finding out what non-customers want is far more likely to garner new customers.
"the hilux is more suitable in canada because the roads are bumpy and the weather makes more potholes than the states--Posted by: a | May 19, 2015 8:04:43 AM"
You haven't visited Pennsylvania lately, have you? Sheesh! What's worse is trying to repair those potholes with "oil and chips"! The patch is almost as bad as the original hole.
I'll tell you one thing, this truck ain't all new. He may be some fancy dancy chief engineer. However, to say this thing is "all new" insults the intelligence of a lot of truck buying consumers/enthusiasts.
It can not be all new if the basic cab body section and the 3/4 of the frame is the same as the current truck. Heavily revised... yes, but definitely NOT all new.
Camry wheel bearings
@jaun
My sienna had Camry bearings and still has two original after 350km
How about rear leg room? The backseats are so cramped.
And why not a diesel engine?
"How about rear leg room? The backseats are so cramped."
-- Who cares? They're never going to be used anyway.
"... but for the price they are asking for them, you are better off getting a much larger truck."
-- Or not, when a much larger truck is simply too big for your purposes.
The comments to this entry are closed.